100% Cotton Double Pique Knit Fabric Dyeing And Finishing Development 2022

Double pk knit fabric is a special type of fabric. Its Dyeing and finishing process is also special in the present world. The dyeing finishing process and its flow chart are unique from other fabrics. Recently I developed a 100% cotton pique knit fabric and I am sharing here my experience with all the process parameters. Here also stated the testing process and actual data of my development according to different ISO testing methods.

Double Pique knit fabric
The finish fabric which I got after development

Double Pique knit fabrics are made of thick single yarns that create a diamond pattern when knitted. The double pique pattern is created by knitting two stitches together and then knitting another stitch in the next hole. This creates a tighter knit than regular pique and creates a more dense and strong fabric with texture to it. Double pique fabrics generally have a thick woven appearance and can be used for many home projects such as kitchen aprons, tablecloths, and placemats.

Target Parameter Double Pique Fabric

BuyerCelio
fabric TypeDoubble pk
Composition100 % cotton
Color NameAs swatch
Shade%5.38
Required Dia 
Required GSM250
Special Note 

Yarn Information

Yarn count and Type22/1 cotton
Yarn composition100 % cotton
Yarn lot307/ 21
Yarn BrandBlank

Knitting Parameter

Machine  Dia and Gauge25*24 G
Total needle1884
Stitch length29
Machine No40
Machine BrandFukuyama
Machine RPM10
Grey Width176 Cm  (open)
Grey GSM
Gray Wash
Gray Wash GSM

Dyeing Flow Chart:

Dyeing  recipe :

Buying House : Practical Textile
Buyer              :  Practical Textile
Order No         : 01
Machine No    : 
Type of fabric :s/j CTN
Sro No             : 
Date              :1.01.22
Batch No       :0000
Shade/Color  :Any
Quantity        :50 Kg
L.:R.              : 
Total Water   :400 Lt
REQUISITION FO DYESTUFF & CHEMICALS
SL#  Name of the chemicalsG/Liter%Req’d Qty. In KgIssues Qty.Remarks
Pretreatment :
1      
2Detergent0.80 0.240  
3Anticrese2.00 0.600  
4Caustic2.00 0.600  
5H2O22.50 0.750  
6      
7      
 Peroxide killer0.15 0.045  
8Acitic Acid1.00 0.300  
9      
10      
11      
12      
Dyeing :                                                              
13Leveling agent1.00 0.300  
14Anticreseing agent2.00 0.600  
15      
16Color : orange1.026% 0.513 gm  
17Color : red1.188 % 0.59 gm 400 mg  
18Color: Blue2.2 % 1 kg 100 gm  
19      
20Gluber Salt70.00 28,000 kg  
21Soda Ash Lt15.00 6,000 kg  
After Treatment :
22Soaping agent0.80 0.240  
23anticreseing agent0.50 0.150  
24      
25Fixer1.00 0.300  
26      
27Softener2.00 0.600  

Dyeing process:

Loading

Detergent+ anticreaseing agent inject

Temperature rise 50 degree

Caustic dossing 5 min

rise the temperature at 70 degree

Hydrogen Peroxide inject

Rise the temperature at 98 degree

run for 60min

cooling and draing

normal hot

peroxide killer inject

acid for neutralization

enzyme

wash then levelling

Temperature 60c

Leveling dosing 3 minute

Runtime 10 minute

Color dosing 25 minutes (Linear)

Runtime 10 minute

1st Salt dosing 10 minute

Runtime 10 minute

2nd salt dosing 10 minute

Runtime 10 minute

Sample check

1st Soda dosing (1g/l) 25 minute

Runtime 10 minute

2nd soda dosing 10 minute

Runtime 10 minute

                                                                          Sample check

If shade ok then

soaping

softener

Actual Dyeing procedure Steps image which i did practically

Double Pique Knit Fabric Dyeing And Finishing

Double Pique knit fabric finishing flow chart:

Slitting Parameter:

Machine Speed40
Padder pressure1.5 kg
Over FeedBlank
Fabric In Diameter25
Fabric Out Diameter170

Stanter/Dryer

NameHeat SetDry Time
Width set170 
Over Feed59 % 
Temperature120 
RPM/ Speed13 
Pedder Pressure312 
Vibrationbiank 
Softener TypeCationic 
After Dry Width170 -165 B dia= 170-163
After Dry GSM250-210B. gsm=250-220
   

Stenter/Compacting

Stanter /Dryer Compacting 
Width set140  
Over Feed59%Temperature120
Temperature120Steam Pressure30
RPM/ Speed13Width set170
Padder Pressure312Over feed%35%
VibrationblankRPM/Speed12
Softener TypeCationicCompaction%blank
After Dry Width170-165After Width170 -163
After Dry GSM250-210After GSM250-220
  Wash gsm250

Shrinkage:

Length=

Width=

SP%=

Test Report:

Final width=    130 f145                                          Final GSM=270 f 265

Shrinkage with tumble dry:

Length= -5%

Width=-5 %

SP%=2%

Shrinkage of line dry:

Length=-1.2%

Width=+2.8%

SP%=2%

Testing of Double pique knit fabric with ISO method:

THe conclusion of the test methods

Sl. No.Test NameResults (A)
01Dimensional Stability to washingPass
02Angular Variation After WashingPass
03Pilling Resistance (ICI BOX Method)Pass
04Mass per unit areaPass

01. Dimensional Stability To Washing

Test Method : NF EN ISO 5077/6330/3759

Wash Condition: Normal Program, Machine wash @40ºC, Line dry, Used Front loading washing Machine Wascator with 15.4gm  ECE reference Detergent, 4gm Sodium Per borate and 0.65gm TAED Solution With 2.0 Kg Load.

Sample (A)After Three Wash 
DirectionResultClient Requirement
Length-1.2%±5%
Width+2.8%

Remark: (+) Means Extension And (-) Means Shrinkage

02. Angular Variation After Washing

Test Method: ISO16322-1: 2005

Wash Condition: Normal Program, Machine wash @40ºC, Line dry, Used Front loading washing Machine Wascator with 15.4gm ECE  reference Detergent, 4gm Sodium Per borate and 0.65gm TAED Solution With 2.0 Kg Load.

Sample (A)Result (After Three Wash)Client Requirement
Spirality0.0%5%

03. Resistance Of Pilling (ICI BOX Method)

Test Method: NF EN ISO 12945-1:2020

Wash Condition: After Three Wash (ISO 6330, Normal Program@40ºC, Line dry)

Sample (A)ResultClient Requirement
After 14, 400 Cycle, 4hrs  
Grade44
Note: Fuzzy Effects were observed 

04. Mass Per Unit Area

Test Method: NF EN ISO 3801: 1977, method 5

Test Stage: As Received Stage

Sample (A)ResultClient Requirement
Average273.5 g/m2280 g/m2 (±5%)

Conclusion:

I discussed the 100% Cotton Double Pique Knit Fabric Dyeing And Finishing Development which I did recently. All the parameters and processes are actual. Anyone can apply the parameter. Any confusion comments me. I will give the solution.

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